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Material Requirement Planning By GROUP-8 Debojit Roy – H66 Sritanu Das Mahapatra – H57 Abhisek Sahu – H3 Krishnakant Pandey – H25 Biswajit Ghosh – H12
Material Requirement Planning ,[object Object],[object Object],[object Object]
END PRODUCT COMPONENT OF END PRODUCT RAW MATERIAL Order Point Time LT LT Time LT Time LT Independent and Dependent Demand Inventory Order Point Order Point LT
The Benefits of MRP ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
WHEN  TO  USE MRP? ,[object Object],[object Object],[object Object],[object Object],[object Object]
Limitations of Order-point techniques… ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],Master  Production  Schedule Material Requirements Planning Product Structure File  Item Master  file Planned Order Release Work  orders Purchase  Orders  Rescheduling  notices
Information Needed for MRP ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
MRP Inputs ,[object Object],[object Object],[object Object]
Product Structure File ,[object Object],[object Object]
Bill of material LEVEL PRODUCT LEAD TIME Level 0 Two -drawer file cabinet Level 1 Case (1) 2 weeks Level 2 Drawer slide (4) 3 weeks Formed case (1) 2 weeks Level 3 Sheet steel (1) 4 weeks Level 1 Drawers (2) 1 week Level 2 Formed drawer (1) 2 weeks Handle (1) 3 weeks Support rollers (2) 3 weeks Level 3 Sheet steel(1) 4 weeks
Master Production Schedule ,[object Object],[object Object],[object Object],[object Object]
Inventory Master File ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Product structure tree Two-Drawer File Cabinet ,[object Object],Two drawer File cabinet Case(1) 2 week Drawers(2) 1 week Drawer slide(4) 3 week Formed case(1) 2 week Sheet steel(1) 4 week Formed  Drawer(1) 2 week Handle(1) 3 week Support Rollers(2) 3 week Sheet steel(1) 4week Level 1 Level 2 Level 3 Level 0
Drawer Subassembly Requirement MPS for two-drawer file cabinet WEEK 1 2 3 4 5 6 GROSS REQUIREMENTS 20 30 40 10 50 60 SCHEDULED RECEIPTS 0 0 0 0 0 0 BALANCE ON HAND  90 70 40 0 -10 -50 -60 PLANNED-ORDER RELEASE 0 0 10 50 60 0 week 1 2 3 4 5 6 quantity 10 15 20 5 25 30
Description ,[object Object],[object Object],[object Object],[object Object]
Description  ,[object Object],[object Object]
SUPPORT ROLLER REQUIREMENTS week quantity 1 2 3 4 5 6 0 0 10 50 60 0 Drawer subassemblies WEEK 1 2 3 4 5 6 GROOS REQUIREMENT 0 0 20 100 120 0 SCHEDULED RECEIPTS 0 40 0 0 0 0 BALANCED ON HAND 60  60 100 80 -20 -120 0 PLANNED-ORDER RELEASE 20 120 0 0 0 0
Two important concepts ,[object Object],[object Object]
Regeneration vs. net change ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Manufacturing Resource Planning  ( MRP II ) ,[object Object]
Business Planning Sales Planning Production Planning Resources OK? Master Scheduling Material Planning Capacity Planning Planning OK? Performance Measurement Shop Floor Control Purchasing Objectives Demands Routing Inventory Status Bills of Material Products Materials Capacity Parts Hours Accountability Objectives Top Management Planning OMP Operations  Management Execution Yes No No Yes F E E D B A C K
Just-in-time (JIT) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
History of JIT ,[object Object],[object Object]
Benefits of JIT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Problems of JIT ,[object Object],[object Object],[object Object]
 
MRP vs. JIT ,[object Object],[object Object]
Summary ,[object Object]

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Material Resource Planning

  • 1. Material Requirement Planning By GROUP-8 Debojit Roy – H66 Sritanu Das Mahapatra – H57 Abhisek Sahu – H3 Krishnakant Pandey – H25 Biswajit Ghosh – H12
  • 2.
  • 3. END PRODUCT COMPONENT OF END PRODUCT RAW MATERIAL Order Point Time LT LT Time LT Time LT Independent and Dependent Demand Inventory Order Point Order Point LT
  • 4.
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  • 11. Bill of material LEVEL PRODUCT LEAD TIME Level 0 Two -drawer file cabinet Level 1 Case (1) 2 weeks Level 2 Drawer slide (4) 3 weeks Formed case (1) 2 weeks Level 3 Sheet steel (1) 4 weeks Level 1 Drawers (2) 1 week Level 2 Formed drawer (1) 2 weeks Handle (1) 3 weeks Support rollers (2) 3 weeks Level 3 Sheet steel(1) 4 weeks
  • 12.
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  • 15. Drawer Subassembly Requirement MPS for two-drawer file cabinet WEEK 1 2 3 4 5 6 GROSS REQUIREMENTS 20 30 40 10 50 60 SCHEDULED RECEIPTS 0 0 0 0 0 0 BALANCE ON HAND 90 70 40 0 -10 -50 -60 PLANNED-ORDER RELEASE 0 0 10 50 60 0 week 1 2 3 4 5 6 quantity 10 15 20 5 25 30
  • 16.
  • 17.
  • 18. SUPPORT ROLLER REQUIREMENTS week quantity 1 2 3 4 5 6 0 0 10 50 60 0 Drawer subassemblies WEEK 1 2 3 4 5 6 GROOS REQUIREMENT 0 0 20 100 120 0 SCHEDULED RECEIPTS 0 40 0 0 0 0 BALANCED ON HAND 60 60 100 80 -20 -120 0 PLANNED-ORDER RELEASE 20 120 0 0 0 0
  • 19.
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  • 21.
  • 22. Business Planning Sales Planning Production Planning Resources OK? Master Scheduling Material Planning Capacity Planning Planning OK? Performance Measurement Shop Floor Control Purchasing Objectives Demands Routing Inventory Status Bills of Material Products Materials Capacity Parts Hours Accountability Objectives Top Management Planning OMP Operations Management Execution Yes No No Yes F E E D B A C K
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  • 29.